Remove/install engine with front axle carrier

AR01.10-P-2500MRF

Remove/install engine with front axle carrier

31.05.2017

Engine

274.9 in model 238

with code M005 (4MATIC)

1

Refrigerant lines

6

Coolant hose

2

Refrigerant line

7

Vacuum line

3

Coolant hose

8

Purge line

4

Coolant hoses

10

Reinforcement

5

Coolant hose

11

Bracket

14

Air conditioning pressure sensor

12

Bolts

15

Low-temperature circuit circulation pump

13

Bolts

16

Low-temperature circuit temperature sensor

22

Fuel hose

23

Steering coupling

25

Diagonal struts

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes on AIR BODY CONTROL

Engine 274.9 in model 238
with code 489 (AIR BODY CONTROL)
with code M005 (4MATIC)

AH32.22-P-1000-03LWO

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Relieve pressure in the AIR BODY CONTROL system with vehicle diagnosis system.

Engine 274.9 in model 238
with code 489 (AIR BODY CONTROL)
with code M005 (4MATIC)



AD00.00-P-2000-06LWO

2

Shift transmission to neutral and release parking brake

3

Disconnect ground line from on-board electrical system battery

AR54.10-P-0003LWO

4

Turn front wheels to straight-ahead position and fix steering wheel in place with holding device


The steering wheel must not be turned when the steering coupling (23) is removed.
Otherwise the clock spring contact will be destroyed.

 Retainer device

*129589012100

5

Secure vehicle on vehicle lift

AR00.60-P-0100CW

6

Remove upper engine cover

 Installation: Only install top engine cover after the leak test.

7

Remove engine compartment paneling

AR61.20-P-1105LWE

 Installation: Only install lower engine compartment paneling after leak test.

8

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01MR

 Dust cap on service valve

*BA07.03-P-1003-01F

 Pressure hose

*119589046300

9

Drain off coolant

AR20.00-P-1142OLC

10

Drain air conditioning system

AR83.30-P-1760LWO

11

Disconnect refrigerant lines (1) at connecting points and close off openings with a suitable stop plug

 Installation: Install new sealing rings.

 Nut/bolt, connecting point for refrigerant line

*BA83.30-P-1004-01R

 Record plug

*129589009100

12

Remove engine air intake duct upstream of air filter housing

13

Disconnect engine wiring harness

AR15.18-P-1000-05MRD

 M61

*BA00.10-P-1002-04A

 Nut, positive line to busbar on firewall

*BA54.18-P-1001-02C

 Bolt/nut, ground line to transmission/underfloor

*BA00.19-P-1039-02B

14

Remove reinforcement (10)

 M81

*BA00.10-P-1004-04A

 M61

*BA00.10-P-1002-04A

 Bolt, lock striker to cross member/front-module carrier

*BA62.30-P-1008-01H

15

Remove refrigerant line (2) from condenser and close off openings using suitable stop plugs

 Installation: Install new sealing rings.

 Nut/bolt, refrigerant line to condenser

*BA83.30-P-1006-01R

 Record plug

*129589009100

16

Remove coolant hose (3) from low-temperature circuit cooler

AR20.20-P-7441-01RQ

17

Release and disconnect fan unit electrical connector

18

Remove coolant hoses (4) from expansion reservoir

AR20.30-P-4949OLC

19

Remove coolant hose (5) from engine

 Hose clamp pliers

*003589033700

20

Remove coolant hose (6) from firewall

AR20.20-P-7441-01RQ

21

Detach vacuum line (7) from vacuum pump

22

Release and disconnect purge line (8) at connecting point

23

Release and disconnect inerting system line on firewall

Engine 274.9 in model 238
with code 2U8 (Alternative refrigerant)
with code M005 (4MATIC)

AR86.10-P-0419LWE

24

Remove holders (11)

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

25

Remove screws/bolts (12, 13)

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

26

Release and disconnect electrical connector (14) on air conditioning system pressure sensor

27

Release and disconnect electrical connector on low-temperature circuit circulation pump (15)

28

Release and disconnect electrical connector on low-temperature circuit temperature sensor (16)

29

Release and disconnect electrical connectors from electric power steering actuator motor

AR46.20-P-0600LWO

30

Unclip wiring harness for electric power steering actuator motor from front axle carrier

AR46.20-P-0600LWO

31

Remove center exhaust system

AR49.10-P-7283MRC

32

Remove fuel hose (22) from engine, catch escaping fuel in a suitable container and close off connections using suitable stop plugs

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

33

Remove drive shaft from transmission output flange

AR41.10-P-0050LW

34

Remove diagonal struts (25)

AR61.10-P-5143LWO

35

Remove steering coupling (23) from steering shaft

AR46.10-P-8000LWO

36

Remove rpm sensors from steering knuckles

AR42.30-P-0713LWO

37

Unclip electrical lines from spring control arms and steering knuckles

38.1

Remove brake caliper with brake linings and with attached brake hose free of tension to the vehicle

Engine 274.9 in model 238
with code M005 (4MATIC)4-piston fixed-caliper brake

AR42.10-P-0070LWQ

38.2

Remove brake caliper with brake caliper supports and fasten unstressed on vehicle

Engine 274.9 in model 238
with code M005 (4MATIC)1-piston floating caliper brake

AR42.10-P-0070LWO

39

Remove steering knuckles from top transverse control arms

AR33.25-P-0400LWQ


Secure the steering knuckle again folding away.
Otherwise the joints will be damaged.

40

Remove suspension struts from spring control arms

Engine 274.9 in model 238
with code M005 (4MATIC)
except code 489 (AIR BODY CONTROL)

AR32.25-P-1017LWO

Engine 274.9 in model 238
with code 489 (AIR BODY CONTROL)
with code M005 (4MATIC)

AR32.25-P-1017LWQ

41

Support front axle carrier, secure engine transmission unit and radiator package with a tensioning strap against slipping and falling down



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

42

Remove rear engine carrier from frame floor assembly

AR22.10-P-4360MRD

 The rear engine support remains on the transmission.

43

Remove front axle carrier screw/bolts from longitudinal member

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01Q

44

Lower engine transmission unit with front axle carrier and radiator package


Lower engine transmission unit with front axle carrier and radiator package.
Otherwise damage will occur.

 Aid of helper required.

45

Install in the reverse order

46

Perform wheel alignment check

AR40.20-P-0200LWO

47

Check engine oil level and correct



AP18.00-P-1811MP

48

Read out and erase fault memory



AD00.00-P-2000-06LWO

49

Calibrate Distance Pilot DISTRONIC controller unit

Engine 274.9 in model 238
with code 239 (DISTRONIC adaptive cruise control)
with code M005 (4MATIC)



AD00.00-P-2000-06LWO

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

50

Perform an engine test run and check engine for proper operation and leaktightness

51

Install lower engine compartment paneling

AR61.20-P-1105LWE

52

Install upper engine cover

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1004-04A

M81

Nm

23

33

 Ground points

Number

Designation

Model 238

BA00.19-P-1039-02B

Bolt/nut, ground line to transmission/underfloor

M8

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1003-01F

Dust cap on service valve

Plastic

Nm

2

Metal

Nm

15

 Front axle carrier

Number

Designation

Model 238

BA33.10-P-1001-01Q

Bolt, front axle carrier to longitudinal member

Nm

180

 Wiring harness

Number

Designation

Model 238

BA54.18-P-1001-02C

Nut, positive line to busbar on firewall

M6

Nm

8

M8

Nm

16

 Cross member and front reinforcement

Number

Designation

Model 238

BA62.30-P-1004-01H

Bolt, strut to soundproofing

M8

Nm

23

 Cross member and front reinforcement

Number

Designation

Model 238

BA62.30-P-1008-01H

Bolt, lock striker to cross member/front-module carrier

Nm

10

 Air conditioning

Number

Designation

Model 238

BA83.30-P-1004-01R

Nut/bolt, connecting point for refrigerant line

Nm

12

 Air conditioning

Number

Designation

Model 238

BA83.30-P-1006-01R

Nut/bolt, refrigerant line to condenser

Nm

12